Structural member construction for building walls

ABSTRACT

One embodiment comprises two structural channel members having edge abutting flanges having flange inner surfaces disposed in co-planar alignment by providing connector plates having first portions disposed against and secured to the inner surfaces of the flanges of one channel member and having vertically spaced apart latching slots formed in the other portions of such plates, the flanges of the other structural member having latch bolts extending inwardly from their inner surfaces to be received in the latching slots of such plates. With the space between the channel members filled, as with concrete, a strong column is provided to space wall sheaths which are mounted upon the opposite outer flange faces of the channel members. In another embodiment, the channel members are latched to one another by means of overlapping-U-shaped connectors secured to the channel members intermediate the flanges thereof. The open end of one such connector is sized to fit snugly over the open end of the other connector, the legs of the outer connector being provided with inner ribs which engage outer ribs on the inner connector in an interlocking manner.

United States Patent Sikes 1 51 Oct. 17, 1972 STRUCTURAL MEMBER CONSTRUCTION FOR BUILDING WALLS [72] lnvcntor: .lohn Slkes, 8535 Findley, Houston,

Tex. 77(ll7 Filed: Dec. 8, 1969 Appl. No.: 882,995

Related US. Application Data Primary Examiner-Frank L. Abbott Assistant Examiner-James L. Ridgill, Jr. Attorney-William E. Ford [63] Continuation-impart of Ser. No. 697,672, Jan.

15, 1968, abandoned. [57] ABSTRACT One embodiment comprises two structural channel [52] US. Cl. ..52/276, 52/582, 52/250 members having edge abutting flanges having flange [51] Int. Cl ..E04l) 1/343, E04b l/ inner Surfaces disposed in co planar alignment by [58] Field of Search 287/64, 65, 103, 2092, providing connector plates having first portions disposed against and secured to the inner surfaces of 287/2092 D, 127, 20.92 G; 52/39 4951 the flanges of one channel member and having verti- 4 2 431, 250, 704, 536, 584, cally spaced apart latchin g slots formed in the other 532 portions of such plates, the flanges of the other structural member having latch bolts extending inwardly from their inner surfaces to be received in the latching slots of such plates. With the space between the chan- [56] References cued nel members filled, as with concrete, a strong column UNITED STATES PATENTS is provided to space wall sheaths which are mounted upon the oppos1te outer flange faces of the channel 3,325,585 6/1967 Brenneman ..52/586 b 336464l H1968 Brenneman In another embodiment, the channel members are 1,211,790 1/1917 Van Orden ..287/l84.36 l t h dt th b f l U 14 714 11/1924 Needham et al 52/293 a c e y means appmg' shaped connectors secured to the channel members Barce i ter edia he fla g he eo e open e of one 2,010,4l 2 Parsons such connector is sized to fit g y Over the p end 2,053,482 9/1936, Kellogg ..52/481 of lhe other connector the |egs of the Outer connector 2,128,797 8/1938 Bohnsack ..52/481 belng provlded with mner r1bs wh1ch engage outer r1bs 2,137,767 1 1/1 938 Betcone ..52/62 on the nn r nn c or in n interlocking manner.

4 Claims, 11 Drawing Figures 55a. .5/ 7 53 C 7 f 574. I1 ///////////7/ (IJ\\\\\\\\\\\\\ k' 55 l 59 -57b 60a 60 56a, 53a. 56L -1//////////////////1/ 56 59 J 53b /7 54C STRUCTURAL MEMBER CONSTRUCTIONFOR BUILDING WALLS CROSS-REFERENCE TO RELATED APPLICATION This application is a continuation-in-part of applicants copending application Ser. No. 697,672 filed on Jan. 15, 1968 now abandoned.

BACKGROUND AND OBJECTS OF THE INVENTION This invention relates to novel and efficient methods and structures for use in erecting the walls of buildings. Though not limited thereto, the present invention is particularly useful in interconnecting prefabricated wall panels.

One object of the invention is to provide new and improved columnar structures for supporting the wall sheaths forming the two sides of a building wall.

Another object of the invention is to provide new and improved columnar structures for forming the corners at the meeting places of pairs of building walls running in different directions.

Other and further objects will be apparent when the specification herein is considered in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view of a corner construction which also shows a columnar construction spaced from the corner and spacing wall sheath sections transversely apart;

FIG. 2 is a plan view of a corner construction, as shown in FIG. 1, the figure also showing a columnar construction spaced to the left of the comer construction and corresponding in construction with the columnar construction shown to the right of the corner construction in FIG. 1;

FIG. 3 is a fragmentary elevational view of a connector plate as used to connect columnar channels in FIGS. 1 and 2;

FIG. 4 is a fragmentary elevational view of a connector plate as used to connect corner members to a corner angle, as shown in FIGS. 1 and 2;

F IG. 5 is an elevational cross-sectional view through a portion of one of the walls shown in FIGS. 1 and 2;

FIG. 6 is a cross-sectional plan view of a modified embodiment of corner construction;

FIGS. 7 and 8 are cross-sectional plan views of the adjacent ends of wall panels which are to be connected to one another, such views showing a modified embodiment of structure for interconnecting the wall panels;

FIG. 9 is an elevational view taken along section line 9--9 of FIG. 7;

FIG. 10 is an elevational view taken along section line 10-10 of FIG. 8; and

FIG. 11 is an enlarged fragmentary view showing in greater detail the interlocking of the interconnecting structures of FIGS. 7 and 8.

DESCRIPTION OF THE ILLUSTRATED EM BODIMENTS Referring now in detail to the drawings in which like reference numerals are applied to like elements in the various views, a building construction 10 is shown in FIGS. 1 and 2 in which a corner construction 11 is shown and also wall constructions 12 and 13 extending from the corner 11 at right angles to each other. An intermediate column and wall sheath spacer construction 14 is shown at the right of the comer 11 in FIG. 1 and to the left of the comer 11 in FIG. 2, which is illustrative of the columnar construction comprising an important portion of this invention.

In detail, a column 14 is shown as comprising upstanding channels 15a, 15b with respective pairs of channel flanges 16a, 16b in outer edge face abutment. Outer and inner upstanding connector plates 17a, 17b are shown disposed against the inner faces of the outer channel flanges 16a and 16b and against the inner faces of the inner channel flanges 16a and 16b, with the flanges 16b being provided with latch bolts or rivets 18 with heads 18a disposed at a spaced distance inwardly from the inner faces of the respective channel flanges 16b, such spaced distance being a distance slightly greater than the thickness of the plates 17a and 17b.

In fabrication, the channel 15b is first placed in proper upright position on a conventional runner or slab 19, as shown in FIG. 5, with the bolts or rivets l8 vertically spaced along flanges 16b at predetermined distances apart. Then the channel 15a (with the left outer faces of the connector plates 17a and 17b secured to the respective inner faces of the channel flanges 16a, as by gluing, welding, bolting, or by any appropriate means) is maneuvered to latch the connector plates 17a and 17b, having therein the appropriately spaced latching slots 20 shown in FIG. 3 over the aforesaid bolts or rivets 18 which extend inwardly from the flanges 16b.

With the opposed or abutting channels 15a and 15b thus positioned and latched together, the inner wall sheaths 21a and outer wall sheaths 21b are disposed against and secured to the outer faces of the channel flanges 16a and 16b of spaced apart aligned columns 14 whereby the wall sheaths 21a and 21b are properly longitudinally aligned and transversely spaced apart. As shown in cross-section in FIG. 5, a wall construction 12 or 13, comprised of wall sheaths 21a and 21b, thus spaced apart, fits at bottom into rectangularly crosssectioned groove means 22 in a concrete slab or runner l9, concrete 23 having been poured to a depth between the wall sheaths or within the column 14 to anchor a wall 12 or 13 to the base or slab 19.

The corner construction 11, as shown in FIGS. 1 and 2, includes an outer corner angle member 24 which may be of the same construction material as the walls 21a and 21b, or of any suitable light material. Then inwardly of the angle member 24, in the finally assembled views of FIGS. 1 and 2, a structural angle 25 is shown, such angle 25 have appropriately, vertically spaced apart bolts or rivets 18 which extend inwardly from the inner faces of the angle legs 25a and 25b. Angle 25 is secured to angle member 24 by gluing, welding, or the like. Also, the corner construction 11 includes a channel 26a across the wall construction 13 to the left, and a channel 26b across the wall construction 12 at ninety degrees to the wall construction 13. Each of the channels 26a and 26b has vertically spaced apart inwardly extending studs 18b mounted on the flange 27a thereof.

A connector plate 280 is shown in FIGS. 1 and 2 as having its left, outer face disposed against and secured to the inner face of the flange 27b of the channel 26a, such connector plate having vertically spaced apart slots 30 in the right-hand side thereof. As indicated in FIG. 4, the slots 30 each have an enlarged upper portion 30a and a smaller, lower portion 30b, for purposes to be hereinbelow described. Also, a second connector plate 28b is shown in FIGS. 1 and 2 as having its right, outer face disposed against and secured to the inner face of the flange 27b of the channel 26b, such plate having vertically spaced apart slots 30, as hereinabove described, in the left-hand side thereof as viewed in FIG. 1. A further angle 29 is shown in FIGS. 1 and 2 as having holes 35 vertically spaced apart in both legs 29a and 29b thereof.

The assembly of the corner construction 11 is accomplished first by disposing channels 260 and 26b in upright positions in the relative plan positions indicated in FIG. 1 and best visualized from FIG. 2. Then the inner angle 29 is placed in proximity to the respective inner flanges 27a of the channels 26a and 26b and in a manner such that the oversized holes 35 receive the studs 18b therein. Next, with the connector plates 28a and 28b in established contact with the channel flanges 27b of the respective channels 26a and 26b, the angle 25 is moved toward the position shown in FIG. 1. As best visualized in FIG. 2, the bolt heads 18a are passed through the larger, uppermost portions 30a of the slots 30 in the connector plates 28a and 28b and then lowered into the smaller, lower portions 30b thereof.

As indicated in FIG. 2, spacer members 32 (and 32a if desired) may be located intermediate the column structures 14 or between the corner column structure 11 and the nearest such column structure 14.

After the corner structure 11 and the wall structures 12 and 13 have been assembled and erected, the centers of the column structures 14 (the regions enclosed by each pair of channel members 15a and 15b) and the center of the corner column structure 11 (the region enclosed by channel members 26a and 26b and angle member 25) are preferably filled with a filler material such as concrete. Such concrete is indicated by reference numeral 33 in FIG. 2. After the concrete hardens, it seals the joint defined by the structural members forming the column structures. Such concrete also provides a weight bearing columnar structure for supporting the next floor level or the roof or the like of the building.

The column structures 11 and 14 are particularly useful for interconnecting prefabricated wall panels. Considering, for example, the column structure 14 shown in FIG. 2, the wall panel structure connected to the channel 150 can be prefabricated at a factory location with the channel 15a and connector plates 17a and 17b mounted in the left-hand end thereof. In a similar manner, the wall panel structure connected to the right-hand channel 15b can be prefabricated at the factory with the channel 15b and latch bolts 18 mounted in the left-hand end thereof. Thereafter, when the wall panels arrive at the building site, they can be quickly connected together by lowering the wall panel having the connector plates 17a and 17b so as to cause the latch bolts 18 to move upwardly into the latching slots 20 in such connector plates 17a and 17b. After the concrete is poured into the center space intermediate the channels 15a and 15b and allowed to harden, a relatively permanent connection of the wall panels is obtained.

Referring now to FIGS. 6-11, there will be described modified forms of construction for the corner and noncorner column structures. Considering first FIGS. 7 and 8, there is shown in a disengaged or disconnected manner the two parts which, when connected together, form a structural column which is located at an intermediate point in a building wall. This column structure includes first and second upstanding structural members and 41. Member 40 is a structural channel member having a web 40a, an inner flange 40b, and an outer flange 40c. The second structural member 41 is also a structural channel member having a web 41a, an inner flange 41b, and an outer flange 41c. Channel member 40 is mounted in the righthand end of a wall panel 42 having wall sheaths 42a and 42b. The second channel member 41, on the other hand, is mounted in the left-hand end of a wall panel 43 having wall sheaths 43a and 43b. When the wall panels 42 and 43 are connected together, the inner flanges 40b and 41b abut one another. Similarly, the outer flanges 40c and 410 likewise abut one another.

The column construction of FIGS. 7 and 8 further includes first connector means 44 mounted on the first structural channel member 40 between the flanges 40b and 400 thereof. This connector means or connector 44 is a generally U-shaped channel member having a web 44a secured to the web 40a of the channel 40 and having a pair of legs 44b and 440 which constitute ribbed elements which extend toward the second structural channel member 41. The ribs are provided by cutting series of longitudinally extending notches in the outer surfaces of the legs 44b and 440. The notches or ribs on leg 44b are indicated at 44d. The notches or ribs on leg 440 are indicated at 44e. As can be seen from the elevational type view of FIG. 9, these ribs 44d and 44e run at right angles to the direction of extension of the legs 44b and 440.

The column structure of FIGS. 7 and 8 also includes second connector means 45 mounted on the second structural channel member 41 between the flanges 41b and 410 thereof. This second connection means or connector 45 is also a generally or approximately U-shaped channel member. As such, the connector 45 includes a web 45a which is secured to the web 41a of the structural channel 41 and a pair of legs 45b and 450 which constitute ribbed elements which extend toward the first structural channel 40. The ribs are indicated at 45d and 45e. These ribs 45d and 45e are formed by cutting series of longitudinally extending notches in the inner surfaces of the legs 45b and 450. These notches or ribs 45d and 45e run at right angles to the direction of extension of the legs 45b and 450.

The second connector 45 is sized so that the legs 45b and 450 thereof will fit snugly over the legs 44b and 44c of the first connector 44. This enables the ribs 45d and 45e to lock in place intermediate the ribs 44d and 44e, respectively, of the first connector 44. This locked condition is shown for a portion of the ribs 44d and 45d in the fragmentary view of FIG. 1 1. The second connector 45 is of a resilient construction for enabling the ribs 45d and 45e thereof to slide over and then lock in place in terrnediate the ribs 44d and 44e of the first connector 44. In a preferred embodiment, the first connector 44 is made of metal and the second connector 45 is made of a resilient plastic material.

Connector 44 is secured to the structural channel 40 by a series of vertically spaced apart bolts or rivets 46. The second connector 45 is similarly secured to the second structural channel 41 by a series of vertically spaced apart bolts or rivets 47.

Considering now the modified comer column construction of FlG. 6, such construction is generally indicated at 50 and is used for forming a corner joint between a pair of wall panels 51 and 52 extending at right angles to one another. The comer structure 50 includes a first upstanding structural channel member 53 mounted in the end of the wall panel 51 and having a web 530 and a pair of flanges 53b and 530 which extend in the direction of the corner of the wall structure. The corner structure 50 also includes a second structural channel member 54 mounted in the end of the second wall panel 52 and having a web 540 and a pair of flanges 54b and 54c which extends in the direction of the desired corner joint. Secured to the first structural channel 53 is first connector 55 in the form of an angle member having a ribbed or notched leg 55a extending in the direction of the common corner location. Secured to the second structural channel 54 is a second connector 56 in the form of a channel-shaped member having ribbed or notched legs 56a and 56b which extend in the direction of the common corner location.

The corner structure 50 further includes an upstanding structure angle member 57 having legs 57a and 57b which adjoin the outer flanges 53c and 54c of the channels 54 and 54, respectively. Secured to the leg 57a is a ribbed element 58 in the form of a bent plate which extends the vertical length of the angle 57. The ribs or notches 58a of the element 58 engage the ribs or notches on the connector 55 in an overlapping and interlocking manner. Secured to the other leg 57b of the angle 57 is a second ribbed element 59 in the form of a bent plate which runs the vertical length of the angle 57. The longitudinally extending ribs or notches 59a of the bent plate 59 engage the ribs or notches on the outer surface of the leg 56a of the second connector 56 in an overlapping and interlocking manner.

The corner structure also includes an inner angle member 60, having one leg 60a secured to the inner flange 53b of the first structural channel 53. Theother leg 60b of the angle member 60 includes a ribbed or notched portion for engaging the ribs or notches on the leg 56b of the connector 56.

In a preferred embodiment of the invention, the connectors and 56 are constructed of a resilient plastic material. These connectors 55 and 56 are secured to their respective structural channels 53 and 54 by means of bolts, rivets, or any other suitable securing mechanism or agent.

The corner structure 50 is assembled by first positioning the outer angle 57 so that the ribs 58a engage the ribs or connector leg 55a and then moving the second well panel 52 into position such that the connector 56 is inserted between the bent plate 59 and the inner angle member 60.

After the various well panels have been erected and various column structure connectors have been interconnected, the interiors or centers of the various FIG. 6-11 type column structures are filled with an appropriate load sustaining material such as concrete.

If desired, some of the teeth forming the ribs on any one or more of connectors 44, 45, 55, and 56 and members 58, 59, and 60 may be of a rounded character instead of a pointed character. Considering'connector 44, for example, the outer tips of all but the right-hand most ones of the teeth 44d and 44e may be rounded off, the right-hand most teeth in each set continuing to have a pointed tip as shown.

While there have been described what are at present considered to be preferred embodiments of this invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the invention, and it is, therefore, intended to cover all such changes and modifications as fall within the true spirit and scope of the invention.

What is claimed is:

l. A structural member construction for building walls comprising first and second upstanding wall panels each including spaced apart, parallel, coterminously extending wall sheaths with end portions separated by respective spacer channels with flanges outermost and coterminous with said end portions whereby in assembly the wall sheath and channel flange end faces may meet in abutment, first connector means of channel construction mountedl centrally in web of channel construction mounted centrally in web abutment on the first wall panel channel web and with first connector flanges spaced inwardly from said first wall panel sheaths, with the outer surfaces of the first connector flanges being ribbed second connector means of channel construction mounted centrally in web abutment on the second wall panel channel web and with second connector flanges spaced. inwardly from said second wall panel sheaths, with the inner surfaces of the second connector flanges being ribbed, and with said second connector flanges being spaced apart and of such flange dimension that when first and second wall panel sheath end faces and spacer channel flange end faces are in respective end face abutment, the second connector flange ribs extend in engagement with the first connector flange ribs just short of the outer face of the web of the first spacer channel, one of said connector means being ofa slightly yieldable plastic and the other connector means being metallic.

2. A structural member construction for building walls comprising building walls in corner abutment comprising first and second upstanding wall panels each including spaced apart, parallel, coterminously extending wall sheaths with end portions separated by respective spacer channels with flanges outermost and coterminous with said end portions, the end portion of the inner wall sheath of said second wall panel being disposed in outer surface abutment with the end face of the inner wall sheath of said first wall panel, and terminating substantially in the extended plane of the inner surface of said first wall panel inner sheath wall, one of said spacer channels having a connector angle member with one leg surface mounted in abutment centrally of the outer surface of one of said spacer channel webs, the other leg of said angle member having outer surface ribbed and space-d inwardly of the adjacent flange of the respective spacer channel on which spacer channel web surface and providing a ribbed surface to extend normal to said back surface and parallel to and spaced from, and facing the inner surface of the outer flange of said other spacer channel, a corner member including a corner angle with angle leg end faces to abut in assembly the respective end faces of the respective wall sheath of said respective wall panels, a connector plate mounted on the inner surface of each leg of said comer angle and providing a respective ribbed inner surface to extend in engaged assembly with the respective ribbed outer surface of the aforesaid other leg of said connector angle member, and providing a respective ribbed inner surface to extend in engaged assembly with the respective connector member ribbed surface, as said corner angle leg end faces are in abutment, as aforesaid, said connector angle and said connector member being of a slightly yieldable plastic and at least the respective connector plates being metallic.

3. A structural member construction as claimed in Claim 2, which additionally includes a metallic angle member with one leg secured to the inner surface of the inner flange of the spacer channel on the web of which a connector angle leg is mounted, and with the angle member other leg extending substantially normal thereto toward the spacer channel web on which a back surface of the connector member is mounted, and in which the angle member other leg provides a ribbed surface engaged in assembly by an inwardly disposed surface provided by said connector member as said connector member comprises a channel type construction.

4. A structural column construction for building wall comers comprising first and second upstanding structural members each having an inner and an outer flange, the flanges of the first member extending at right angles to the flanges of the second member with both sets of flanges facing a common building wall corner location, such structural members respectively including first and second connector means each having a ribbed element extending toward the common corner location, and an upstanding structural angle member having legs adjoining the outer flanges of the first and second structural members, such legs including ribbed elements engaging the ribbed elements of the first and second connector means in an overlapping and interlocking manner, said first and said second connector means being of slightly yieldable plastic. 

1. A structural member construction for building walls comprising first and second upstanding wall panels each including spaced apart, parallel, coterminously extending wall sheaths with end portions separated by respective spacer channels with flanges outermost and coterminous with said end portions whereby in assembly the wall sheath and channel flange end faces may meet in abutment, first connector means of channel construction mounted centrally in web of channel construction mounted centrally in web abutment on the first wall panel channel web and with first connector flanges spaced inwardly from said first wall panel sheaths, with the outer surfaces of the first connector flanges being ribbed second connector means of channel construction mounted centrally in web abutment on the second wall panel channel web and with second connector flanges spaced inwardly from said second wall panel sheaths, with the inner surfaces of the second connector flanges being ribbed, and with said second connector flanges being spaced apart and of such flange dimension that when first and second wall panel sheath end faces and spacer channel flange end faces are in respective end face abutment, the second connector flange ribs extend in engagement with the first connector flange ribs just short of the outer face of the web of the first spacer channel, one of said connector means being of a slightly yieldable plastic and the other connector means being metallic.
 2. A structural member construction for building walls comprising building walls in corner abutment comprising first and second upstanding wall panels each including spaced apart, parallel, coterminously extending wall sheaths with end portions separated by respective spacer channels with flanges outermost and coterminous with said end portions, the end portion of the inner wall sheath of said second wall panel being disposed in outer surface abutment with the end face of the inner wall sheath of said first wall panel, and terminating substantially in the extended plane of the inner surface of said first wall panel inner sheath wall, one of said spacer channels having a connector angle member with one leg surface mounted in abutment centrally of the outer surface of one of said spacer channel webs, the other leg of said angle member having outer surface ribbed and spaced inwardly of the adjacent flange of the respective spacer channel on which said angle member is mounted, the other of said spacer channels having a connector member with a back surface thereof mounted in abutment centrally of the spacer channel web surface and providing a ribbed surface to extend normal to said back surface and parallel to and spaced from, and facing the inner surface of the outer flange of said other spacer channel, a corner member including a corner angle with angle leg end faces to abut in assembly the respective end faces of the respective wall sheath of said respective wall panels, a connector plate mounted on the inner surface of each leg of said corner angle and providing a respective ribbed inner surface to extend in engaged assembly with the respective ribbed outer surface of the aforesaid other leg of said connector angle member, and providing a respective ribbed inner surface to extend in engaged assembly with the respective connector member ribbed surface, as said corner angle leg end faces are in abutment, as aforesaid, said connector angle and said connector member being of a slightly yieldable plastic and at least the respective connector plates being metallic.
 3. A structural member construction as claimed in Claim 2, which additionally includes a metallic angle member with one leg secured to the inner surfaCe of the inner flange of the spacer channel on the web of which a connector angle leg is mounted, and with the angle member other leg extending substantially normal thereto toward the spacer channel web on which a back surface of the connector member is mounted, and in which the angle member other leg provides a ribbed surface engaged in assembly by an inwardly disposed surface provided by said connector member as said connector member comprises a channel type construction.
 4. A structural column construction for building wall corners comprising first and second upstanding structural members each having an inner and an outer flange, the flanges of the first member extending at right angles to the flanges of the second member with both sets of flanges facing a common building wall corner location, such structural members respectively including first and second connector means each having a ribbed element extending toward the common corner location, and an upstanding structural angle member having legs adjoining the outer flanges of the first and second structural members, such legs including ribbed elements engaging the ribbed elements of the first and second connector means in an overlapping and interlocking manner, said first and said second connector means being of slightly yieldable plastic. 